2012-36-0450

Experimental and numerical analysis on coil springs preset plastic deformation

Barbosa, Robinson Ferrari
R&D Engineer at ThyssenKrupp Bilstein Brasil robinson.barbosa@thyssenkrupp.com

Arajo, Wesley da Costa

Product Development Engineer at ThyssenKrupp Bilstein Brasil wesley.araujo@thyssenkrupp.com

Scuracchio, Bruno Geoffroy

R&D Engineer at ThyssenKrupp Bilstein Brasil bruno.scuracchio@thyssenkrupp.com

Curitiba, Jos Roberto

R&D Manager at ThyssenKrupp Bilstein Brasil jose.curitiba@thyssenkrupp.com
Copyright 2012 SAE International

ABSTRACT
The preset process is largely applied on coil spring manufacturing. It is mainly used to guarantee, under work load, that the spring doesnt plastically deform changing the original dimensional restrictions. However, the difficult to predict its behavior under permanent strain is a constraint on projects. All the spring calculations are based on its final geometry (after the preset process), and today the initial geometry definitions are based on empirical information. The aim of this paper, through F.E.M. and experimental work, is to comprehend the stress-strain phenomena involved on the preset process, in order to create a new methodology to design coiling tools.

plastic deformation, the spring is previously set , just after heat treatment, beyond the elastic range. This process is done under warm condition (100o C to 300oC) to benefit from a reduced yield strength and increased plasticity. This operation is called preset. However, this plastic deformation depends on many variables such as temperature, load, stiffness, hardness, among others. All these variables increase the complexity of a deformation prediction model. The objective of this paper is to evaluate the plastic deformation of a coil spring preset through: finite element method, prototypes, and analytical calculation software.

INTRODUCTION
The compression coil springs are mainly used in automotive suspension systems and braking. Its main function is to absorb and dissipate energy during work. As an elastic component, all its deformation occurs within the elastic range determined by Hooke's law. Since the main objective is mass reduction, the mechanical stress level is increasingly high. Thus, the springs are designed closer to yield strength, increasing the risk of sagging along vehicle usage. To avoid that the springs work close to the elastic limit after vehicle assembly, and by consequence suffers permanent

MATERIALS AND METHODS

It will be shortly described all the necessary steps for this analysis, aiming a complete comparison between coil geometry before and after preset plastic deformation. (fig. 1)

Figure 1 Real setup for preset process Figure 2 Spring assembled for stress analysis

INITIAL SPRING DESIGN Initially, spring geometry is created based on information coming out from the vehicle design. According to comfort specification, suspension lay-out, etc., the load and spring height are defined. The spring rate required by the costumer must also be respected. Based on this information, the final spring geometry calculation is determined using specific softwares developed by ThyssenKrupp Bilstein: a design software (Coil Spring Design), and an analytical calculation software (Coil Spring Simulation). LEAD SCREW DESIGN One of the difficulties on a spring design is to predict the spring geometry before the preset process, just after coiling operation. The preset process involves increased plastic deformation and other non-linear characteristics that are not completely controlled by the designers. Therefore, the estimated geometry before preset which guarantees, after plastic strain, the final spring geometry, is the key for a successful spring development. Nowadays only empirical knowledge is applied on this geometry prediction, and because of this empirical characteristic it is usual to perform several tooling adjustments during the trial run that involves high expenses and delay on the project schedule. EXPERIMENTAL NUMERICAL CORRELATION To assure the reliability of F.E.M. results, an experimental stress measurement using gauges was performed, based on a tridimensional measure system. The experiment setup was performed as figure 2 shows:

The gauges were positioned using the coiling side as a reference: 1) 7.27 coil; 2) 6.01 coil; 3) 4.61 coil; 4) 2.27 coil 5) 0.99 coil APPLIED LOADS After setup, a displacement was applied on the spring following these load steps: First step: 0 20mm Second step: 20 120mm Third step: 120 240mm The strain measured by the gauges [S] was converted to stress based on material elasticity modulus.

Table 1 Strain measurements

Strain (S) Strain (S) Strain (S) Strain (S)

Point 1 Point 2 Point 4 Point 5

Displacement (mm) 0-20 20 - 120 120 - 240 251 869 1491 418 2538 3675 33 543 1058 358 2700 3764

FINITE ELEMENT MODEL The finite element model was created based on the spring geometry before the preset process, developed on the previous step. The entire model was created with a Abaqus preprocessor designed by ThyssenKrupp Bilstein.

First order hexahedral elements were used to mesh the spring, and the plates were defined as rigid bodies.

Table 2: Elements corresponding to the measuring points : MEASUREMENT POINTS NUMBER ELEMENT 112115 107882 99557 90158

Total number of nodes: 34954 Total number of elements: 29744 1723 quadrilateral elements of type R3D4 21 linear triangular elements of type R3D3 24000 linear hexahedral elements of type C3D8I 4000 linear wedge elements of type C3D6

1 2 3 5

The analysis was divided in five calculation steps: 1st step: Increase the spring temperature up to 920C 2nd step: Cool the spring to 20C

The final model was designed based on experimental correlation parameters previously obtained, added with a stress-strain curve obtained at 200 C. This tensile test was executed with samples taken from the same batch of springs batc used in this study (same raw material, same tempering hardness, processed together).

PRESET OPERATION 3rd step: Increase the spring temperature up to 200C 4th step: Load with displacement up to block height 5th step: Return to the initial position (load removal load removal) 6th step: Cooling to room temperature ht, To check the final height, rate and load at the design height, although the finite element model is correlated, six springs were preseted until block height. The specimens were heated height at a temperature of 200 C and then compressed until full coil 0 contact. Then, the load was removed and the springs were aircooled to room temperature. Thereafter, the design parameters temperature mentioned were measured. These measurements serve as parameters for checking the results of the finite element model with experimental data.

The figure 3 shows the finite element mesh used on this paper. paper

RESULTS
FINITE ELEMENTS RESULTS AND CORRELATION The finite element model has been correlated with an experimental stress measurement. After application of the three steps of displacement, the strain was measured on these points previously identified. By Hooke's law, the max. Principal Stress was obtained and compared with the finite tress obtaine element model.

Figure 3 - Finite element model

The table 2 shows the elements corresponding to the measuring points, where the gauges were placed.

The table 4 shows the comparison between design parameters like stress and correlation index.

Table 4 Comparison between design parameters Load Step = 120 mm Experimental Strain (S) 869 2538 2760 2700 FEM Correlation Real vs FEM 98% 98% 92% 94%

Max Principal Max Principal (MPa) (MPa) 173.8 507.6 552 540 177 515.9 510.3 508

Fig. 4 Comparison : real vs. FEM before and after preset son

From the finite element model was taken the coordinates from the generating line of the spring geometry. With these data the spring was recalculated in Coil Spring Simulation software, and the results are on the table 3. 3

Table 3 Comparison between process parameters

Spring Rate (N/mm) REAL FEM Load (N) Free Height (mm)

17.9 9 17.4 4 3% %

1670 1720 2%

341 347 2%

Figure 5 Von Mises stress results Von

ERROR

The final springs have been evaluated after the preset. Were en pre being checked the rate, height, diameter, and the height in control load, between other geometrical features. ,

DISCUSSION The results of the design parameters measured from the finite element deformed geometry model show a high correlation with experimental results. The free height had an error of 2%, the rate an error of 3%, and the height in control load an error of 2%. Moreover, a comparison was made between the initial geometry, obtained from the software Coil Spring Design and Coil Spring Simulation, and the geometry generated from the FEM. The results also show a good correlation between the Coil co Spring Simulation software and Abaqus. However, the former is not able to predict the plastic deformation from preset.

The figure 6 shows the spring generating line obtained from the three-dimensional measuring system and the spring generating line obtained from the finite elements model.

REFERENCES
[1] SHIMOSEKI, M., IMAIZUMI, T. FEM for Springs. Berlin. Springer-Verlag, 2003. [2] WAHL, A. M., Mechanical Springs. New York, edition 2, Spring Manufactures Institute, 1991. [3] SHIGLEY, JOSEPH E., MISCHKE, CHARLES R., BUDUNAS, RICHARD G. Projeto de Engenharia Mecnica, Bookman, edition 7, 2005. [4] CHIAVERINI, V. Tecnologia Mecnica Vol. I: Estrutura e Propriedades das ligas metlicas. 2ed.. Makron Books. So Paulo: 1986. [5] CURITIBA, J. Molas helicoidais. In:,6,2005, Anais. Belo Horizonte. ThyssenKrupp Bilstein,2005. [6] NORTON, R. L. Projeto de mquinas: uma abordagem integrada. 2ed. Porto Alegre: Bookman, 2004.

FEM Experimental

ACKNOWLEDGMENTS
The authors would like to thank all ThyssenKrupp Bilstein colleagues for all the discussions and contributions to this paper and Ms. Mariana Batista and her team from Smarttech, for the support on the Abaqus calculations.

Figure 6 Spring F.E.M. generating line and experimental generating line

CONCLUSIONS
The presented methodology was able to predict, with good adherence, the phenomena of plastic deformation during preset. The combination of FEM correlated model, and stressstrain curves from the same material of the analyzed spring, is a very accurate tool. The good correlation between the analytical software and the F.E.M. software has provided good reliability on final geometries of both cases. Thus, the biggest challenge is to reproduce the plastic deformation involved in the process. For future papers the authors suggest to model the plastic deformation during the preset by functions that are able to describe the field strain, or proportionally indicate the deformation as a function of temperature during the preset. This can greatly reduce the time spent in try-outs and tooling adjustments.